Boardwalk system with tread-locating beams

ABSTRACT

A boardwalk system including a first beam and a second beam spaced apart from the first beam. The first and second beams each include a notch formed therein. The system further includes a plurality of generally horizontally arranged treads, each tread being received in the notch of the first beam and the notch of the second beam. At least one of the first and second beams extends across a span.

The present invention is directed to a boardwalk system, and more particularly, to a boardwalk system with beams configured to receive a tread in the desired position.

BACKGROUND

Modular decking systems often include a beam or set of beams which support a set of treads thereon. The treads typically extend generally horizontally and provide a generally flat surface upon which a user can walk, ride small vehicles, etc. However, in many existing modular decking systems, the outer edges of the treads often extend outwardly beyond the beams in a cantilever fashion, making it difficult to locate the treads in the proper position.

SUMMARY

In one embodiment, the present invention includes beams with a tread-locating notch, vertical lip or the like such that treads can be easily placed in the notch or adjacent to the lip. More particularly, in one embodiment the invention is a boardwalk system including a first beam and a second beam spaced apart from the first beam. The first and second beams each include a notch formed therein. The system further includes a plurality of generally horizontally arranged treads, each tread being received in the notch of the first beam and the notch of the second beam. At least one of the first and second beams extends across a span.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front perspective view of a portion of a boardwalk system;

FIG. 2 is side cross section taken along line 2-2 of FIG. 1, and with a handrail system;

FIG. 3 is a side cross section of an alternate boardwalk system, incorporating a curb feature; and

FIG. 4 is a front view of a connector which can be used to couple a tread to an underlying beam.

DETAILED DESCRIPTION

As shown in FIG. 1, in one embodiment the boardwalk system 10 includes a plurality of piles, footings, or bases 12, each of which supports one or more horizontally-extending supports or abutments 14 thereon. Each pile 12 may rest upon (and/or extend below) a ground surface, and elevate the supports 14 to the desired position. In the illustrated embodiment, each pile 12 is generally cylindrical, although the piles 12 can take any of a wide variety of shapes and configurations. Alternately, if desired, the piles 12 can be omitted from the system 10, and the supports 14 can be positioned directly on the ground surface. In this case the supports 14 can be sized to provide the desired clearance between the other components of the system 10 and the ground.

The supports 14 defines a gap 16 therebetween, which is spanned by a pair of beams 18 such that the beams 18 are not supported by any underlying structure along the gap 16. In the illustrated embodiment, each beam 18 extends between a pair of spaced supports 14 positioned at opposite ends thereof such that each support 14 supports two beams 18 thereon. However, this arrangement can be varied such that each beam 18 is supported by, for example, only a single support 14, in which case the beams 18 may be supported at their other ends by the earth or other structures.

Each beam 18, in turn, supports a plurality of generally horizontally extending treads or planks 20 thereon. In the illustrated embodiment, each tread 20 is positioned generally perpendicular to the underlying beams 18 (parallel to the supports 14), and is supported by two parallel, spaced-apart beams 18 thereunder, spanning a gap 22 positioned between the beams 18. However, this arrangement can be varied such that each tread 20 is supported by, for example, only a single beam 18, in which case the tread 20 may be supported at its other end by the earth or other structures.

In the illustrated embodiment each tread 20 is shaped as a generally rectangular prism having a flat upper surface. Moreover, in the illustrated embodiment, each upper surface is generally flat and planar, and positioned relatively close to the upper surface of an associated tread 20 such that upper surfaces together define a generally smooth surface (with gaps between the treads 20, in some cases) which can be walked upon, ridden upon (by small vehicles), etc. If desired, each tread 20 may be coupled to an adjacent tread 20 by, for example, a laterally-extending tongue (not shown) received in an associated groove (not shown) in an adjacent tread 20.

The piers 12, supports 14, beams 18 and treads 20 can be made from any of a wide variety of materials, including, but not limited to, concrete, steel, wood, wood composite materials or other composite materials, or be made entirely or primarily of concrete. Modular decking systems having some features similar to those shown and described herein are disclosed in U.S. Pat. No. 5,906,084 to Millington et al.; U.S. Patent Application Publication Nos. US2009/0301024 and US2010/0186338 to Rischmueller et al, and U.S. patent application Ser. No. 13/149,375, entitled CONNECTOR FOR BOARDWALK SYSTEM and filed on May 31, 2011. The entire contents of the above-identified patent and patent applications are incorporated by reference herein.

As shown in FIGS. 2 and 3, each beam 18 may have a tread-locating notch 24 formed therein, with each notch 24 being defined by a generally vertically-extending lip 26 adjacent an outer end thereof. The lips 26 of the opposed beams 18 are spaced apart by a distance equal to or slightly greater than the length of a tread 20 (i.e. the distance may be no more than 1%, or 5%, greater than the length of the tread 20). In this manner, during assembly of the system 10 each tread 20 can be dropped into place and closely received in the notches 24 such that the tread 20 is effectively locked in placed, and prevented from any significant movement in the longitudinal direction of the tread 20. The system 10 also provides ease of installation, as no fasteners are required to longitudinally lock the treads 20 in place.

As noted above, each beam 18 may operate as a beam in the engineering sense in that each beam 18 spans the gap 16 between the supports 14 (FIG. 1). Each beam 18 may have a length of, for example, at least about five feet in one case, and at least about ten feet in another case, and at least about twenty feet in yet another case. Thus, each beam 18 may need to be configured to resist/accommodate bending moments, and thus may be made of reinforced concrete. The reinforcing member in each beam 18 may be standard rebar or the like, and the rebar/reinforcing member may be pre-tensioned to accommodate the bending moments applied to the beams 18.

Moreover, in order to support the treads 20 carried thereon, each beam 18 may be configured to have a significant portion underlying each tread 20. In particular, each beam 18 may include a underlying position 30 (FIG. 2) positioned below the associated notch 24 and configured to support a tread 20 thereon, and an end portion 32 not positioned below the notch 24 (i.e. positioned outside of the lip) 26. The underlying portion 30 may have a length L₁ (in the direction of the length of a tread 20; see FIG. 2) that is greater than the length L₂ of the end portion 32 to provide sufficient support to the treads 20 carried thereon. In particular, the underlying portion 30 may have a length L₁ at least about 1.5 times, or at least about 2 times, the length L₂ of the end portion 32 to provide sufficient support.

Since each beam 18 is, in one case, supported only at its ends, and is not continuously supported, the extra length of the underlying portion 30 may be required to provide sufficient support. Moreover, each underlying portion 30 may have a thickness (extending in the vertical direction) that is more that twice the thickness of the associated treads 20 supported thereon. This increased thickness of the underlying portion 30 may help to lend stiffness to the beams 18 and enable the beams 18 to support loads and resist bending.

In one case, the notch 24/lip 26 of the beams 18 may have a vertical height about equal to that of the thickness/vertical height of the treads 20. In this case, when the treads 20 are received in the associated notch 24, the top surface of the treads 20 are about flush with the top surface of the beam 18/end portion 32. Alternately, the notch 24/lip 26 may have a vertical height greater than the vertical height of the tread 20, and the beam 18/end portion 32 may extend above the tread 20, as shown in FIG. 3. This feature may be used to provide a curb, and a more finished appearance to the system 10. It is also possible that the notch/lip 26 may have a vertical height less than the vertical height of the tread 20 to provide a recessed feature.

As shown in FIG. 1, each support 14 may also have a lip 34/notch 36 which supports the beams 18 thereon. The lip 34/notch 36 may be sized and configured such that the top surface of the beam 18 and/or the adjacent treads 20 are flush with the top surface of the support 14. This may be particularly important in the case, as shown in FIG. 1, wherein the supports 14 extend generally perpendicular to the beams 18 and parallel to the treads 20, since in this case the supports 14 extend across the walking path of the boardwalk system 10. In this case it may be important that the supports 14 do not protrude significantly upwardly so as to not form a tripping hazard. In some cases, however, it may be desired that each support 14 protrude upwardly, or be recessed below, the top surface of the beams 18 and/or treads 20 to form a curb/speed bump, or a gutter or the like. Each support 14 may have an underlying portion and an end portion with the same features and relative dimensions as outlined above for the underlying portion 30 and end portion 32 of the beams 18.

In some cases, it may be desired to couple the treads 20 to the underlying beams 18 to counteract uplift forces, such as wind, water or hydraulic forces or the like. As shown in FIGS. 2 and 3, all or selected ones of the treads 20 include one or more pre-formed recess 40 located on the underside thereof, and at opposite ends thereof. Similarly, selected ones or all of the beams 18 may include a plurality of pre-formed recesses 42 formed therein. Each beam recess 42 may be aligned with an associated tread recess 40 to together cooperate to form an opening 44 which can receive a connector 46 therein. In particular, FIGS. 2 and 3 illustrates a connector 44 positioned in each of the openings 44/aligned recesses 40, 42.

As best shown in FIG. 4, each connector 46 may be generally “I” or “H”-shaped or dog-boned shaped, having a central stem 48 and a pair of opposed protrusions 50 located at or adjacent to the end of the central stem 48. In the illustrated embodiment, the central stem 48 is generally tubular/cylindrical and elongated, and terminates at the center of each protrusion 50, which is also tubular/cylindrical.

In one embodiment, each connector 46 may be made of a generally elastic material such that each connector 46 can be deformed and return to its original shape after the deforming forces are removed. Each connector 46 can be made of urethane or a urethane-based material, rubber, synthetic rubber, or other materials. In some cases, then, the connectors 46 can thus be entirely made of a non-ferrous material which resists corrosion, particularly in salt environments.

In order to use the connector 46 to couple a beam 18 and a tread 20, the connector 46 is inserted into the opening 44/aligned recesses 40, 42. In one case, in order for the connector 46 to be fully seated in the opening 44, the connector 46 needs to be stretched along its length. In one embodiment, the connector 46 remains under tension when fully seated in the opening 44 to pull the tread 20 and beam 18 tight and secured together. Alternately, the connector 46 fully returns to its un-deformed shape when seated in the opening 44 but still secures the tread 20 and beam 18 and prevents them from being vertically separated. Further details relating to the connector 46 can be found in U.S. patent application Ser. No. 13/149,375, entitled Connector for Boardwalk System, filed on May 31, 2011, the entire contents of which are incorporated by reference herein.

Having described the invention in detail and by reference to certain embodiments, it will be apparent that modifications and variations thereof are possible without departing from the scope of the invention. 

1. A boardwalk system comprising: a first beam; a second beam spaced apart from said first beam, said first and second beams each including a notch formed therein; and a plurality of generally horizontally arranged treads, each tread being received in said notch of said first beam and said notch of said second beam, wherein at least one of said first and second beams extends across a span.
 2. The system of claim 1 wherein said first and second beams each extend across a span.
 3. The system of claim 1 further comprising a first support supporting said first and second beams thereon, the system further comprising a second support supporting said first second beams thereon, said first and second supports being spaced apart and defining a gap therebetween which is spanned by said first and second beams.
 4. The system of claim 3 wherein each support has a notch therein which receives said first and second beams thereon.
 5. The system of claim 4 wherein a top surface of each support is generally flush with a top surface of said plurality of treads.
 6. The system of claim 4 wherein a top surface of each support is generally flush with a top surface of said first and second beams.
 7. The system of claim 3 wherein said first and second beams are generally parallel and extend generally horizontally, and wherein said treads and said first and second supports extend generally horizontally and generally perpendicular to said first and second beams.
 8. The system of claim 3 further comprising a plurality of piers supporting said supports thereon.
 9. The system of claim 1 wherein said treads, said first beam and said second beam are substantially made of concrete.
 10. The system of claim 9 wherein said first beam and said second beam are substantially made of concrete reinforced with a pre-tensioned reinforcing member.
 11. The system of claim 1 wherein each beam includes an underlying portion positioned below the associated notch and an end portion not positioned below said notch, and wherein said underlying portion and said end portion each have a length extending generally parallel to an associated tread carried thereon, and wherein said length of said underlying portion is greater than said length of said end portion.
 12. The system of claim 1 wherein each notch has a vertical height about equal to a thickness of each tread carried thereon.
 13. The system of claim 1 wherein a top surface of each beam is generally flush with, or positioned vertically above, a top surface of said plurality of treads.
 14. The system of claim 1 wherein said first and second beam each have a length of at least about ten feet.
 15. The system of claim 1 wherein at least one of said treads has a pre-formed recess, and at least one of said beams has a pre-formed recess, and wherein the system further includes a connector positioned in said recesses of said at least one tread and said at least one beam and connecting said at least one tread to said at least one beam, wherein said connector limits the movement of said at least one tread upwardly away from said at least one beam.
 16. The system of claim 15 wherein said connector includes a central stem and a pair of opposed protrusions, each protrusion being positioned at or adjacent an end of said central stem, and wherein said recess of said at least one tread receives one protrusion therein and said recess of said at least one beam receives the other protrusion therein.
 17. The system of claim 1 wherein said first and second beams each include a lip defining the associated notch, and wherein said lips are spaced apart a distance slightly greater than a length of the associated treads received therein to closely receive said associated treads therein.
 18. A boardwalk system comprising: a first beam; a second beam spaced apart from said first beam, said first and second beams each including a notch formed therein; a plurality of generally horizontally arranged treads, each tread being received in said notch of said first beam and said notch of said second beam; a first support supporting said first and second beam thereon; and a second support supporting said first second beams thereon, wherein said first and second supports extend generally parallel to said treads.
 19. The system of claim 18 wherein said first and second supports are spaced apart and define a gap therebetween which is spanned by said first and second beams.
 20. The system of claim 18 wherein said first and second beams are spaced apart and define a gap therebetween which is spanned by said plurality of treads.
 21. The system of claim 18 wherein each support has a notch which receives said first and second beams therein.
 22. The system of claim 18 wherein a top surface of each support is generally flush with a top surface of said plurality of treads.
 23. The system of claim 18 wherein said plurality of treads, said first beam, said second beam, said first support and said second support are each substantially made of concrete.
 24. A boardwalk system comprising: a plurality of generally horizontally arranged treads; a beam positioned at or adjacent to one end of at least one of said plurality of treads and extending generally perpendicular to at least one tread, said beam including a generally vertically extending lip positioned adjacent to the associated end of said at least one tread; and at least two supports supporting said beam thereon, each support being spaced apart with a gap therebetween, wherein said beam spans said at least one gap.
 25. A method for assembling a boardwalk system comprising: accessing a first beam and a second beam, wherein said first and second beams each include a notch formed therein; positioning said first and second beams such that they are spaced apart and each extend across a span; and positioning a tread in said notch of said first beam and said notch of said second beam such that said tread is closely received in said notches to limit movement of said treads in a longitudinal direction thereof. 